Process of smelting iron.



UNITED STATES PATENT OFFICE.

MARCUS RUTHENBURG, OF PHILADELPHIA, PENNSYLVANIA.

' PROCESS OF SMEL'IING IRON.

Application filed. February 13, 1903.

To all whom it may concern:

Be it known that I, IVIAROUS RUTI-IEN- BURG, of Philadelphia, in theState of Pennsylvania, have invented certain new and useful Improvementsin Processes of Smelting Iron, whereof the following is a specification.

My improvements comprise a smelting and refining process employing pigiron and iron ore in an ordinary foundry cupola or vertical stackfurnace, as hereinafter described, and characterized by the productionof a quantity of iron, approximating that originally contained in theentire charge of pig and ore, and of a quality superior to the originalpig and ore in that it contains less sulfur and phosphorus, and is offiner grain, and of greater strength than the original pig.

The process consists in mixing ordinary pig iron and iron ore m definiteproportions; charging the same in a vertical stack furnace; subjectingthe mass to a fusing temperature, and, thereby producing two products;first iron containin less sulfur and phosphorus than the original pigiron or ore and second, ferruginous cinder containing the greaterportion of the sulfur and phosphorus before embodied in the original pigiron and ore.

The following is cited as an example of the aforesaid process '.-Iakinga definite weight of an ordinary pig iron, known to the trade as #2 XBuffalo, an analysis of which showed .75 P., .15 S, and 3.25 0.; I mixedsaid iron with an equal weight of an ordinary iron ore in lumps, ananalysis of which latter showed 62.7 Fe, .6 I., and .12 S., and chargedsaid mixture in an ordinary foundry cupola furnace. Upon subjecting themass to heat, by combustion of an amount of coke in said furnace, equalin weight to approximately 15 per cent. of the weight of the charge ofpig iron and ore; an iron product was formed which amounted in weight to80.75 per cent. of the aggregate weight of said original pig iron andore. An analysis of said iron product showed .50 P., .095 8., and 2.000., and,

the production of said iron was accom anied by the formation of a cinderwhici was highly ferruginous, showing upon analysis 51.51 Fe, 26.00SiO,,, .775 P., and .25 S. Said iron product when cast in pigs was foundto be of 50 per cent. greater tensile strength than the original pigiron, and superior thereto in every respect, its fracture being finegrained and silky.

Specification of Letters Patent.

Patented Sept. 8, 1908 Serial No. 143,230.

It may be noted that if the original ore aforesaid had been melted byitself, (the stack being low and the melting rapid,) no reduction wouldhave taken place. Of course, the 1.5 of carbon taken from the pig ironwould not satisfy the oxygen of the ore, and, therefore, it may beassumed that the reaction occurred with the mass in a fused state, theore robbing the metal of carbon and the metal being replenished withcarbon from the coke; the metal in the mixture acting thus as a carrierof carbon to the ore.

In view of the fact that ordinary practice of iron melting in a cupoladoes not permit the admixture of any ore with the pig iron which is tobe melted; and, that ordinary iron refining requires the employment ofan open hearth furnace; it is to be observed that my present process isadvantageous, first, in that approximately an equal quantity of ore maybe mixed with the pig iron, thus, with a minimum amount of fuel; winningthe iron direct from the ore and refining the pig used; and second, thatan ordinary foundry cupola furnace may be employed instead of an openhearth furnace, or an expensive blast furnace for reducing the ore. Bothof the aforesaid features of my process tending to economy of labor,time and fuel in the production of the iron, it is obvious that, by theemployment of my process, a given quantity and quality of iron may beproduced at less cost than hitherto possible.

For economical reasons, it is desirable to employ as large a proportionof ore as is possible in mixture with the particular pig iron to beused, and I find that the definite proportions may be advantageouslyvaried in accordance with the grade of pig iron and ore em loyed,without departing from the essentia features of my invention. Therefore,I do not desire to limit myself to the precis proportions stated.

I do not desire to broadly claim the feature of mixing iron and ore, forsuch mixtures are employed in the well known "pig and ore processes ofmanufacturing steel and wrought iron. However, such known processes areof course distinguished from my present process by the difierentcharacter of product obtained, and by the fact that open hearth,puddling or boiling furnaces are required for them. Moreover, said oldprocesses are characterized by the agitation of the mixture during theprocess, by rabbling, boiling etc., and

are thus further distinguished from my present process, wherein themixture is not agitated.

I claim:

1. The herein described process which consists in mixing unburned pigiron and nonmanganic iron oxid ore, in definite proportions; chargingthe same in a vertical stack furnace; preventing agitation of said masswhile subjecting it to fusing temperature in said furnace, and, therebyproducing two products; first, iron containing less sulfur andphosphorus than said pig iron; and, second, cinder containing sulfur andphosphorus derived from said pig iron.

2. The hereinbefore described process which cons sts in mixing ordinarypig iron and non-manganic iron oxid ore in approxi mately equalparts byweight; charging the same in a vertical stack furnace; preventingagitation of said mass while subjecting it to fusing temperature in saidfurnace, and, thereby producing two products; first, iron representingthe amount in said' pig plus the greater part of that in said ore, andcontaining less sulfur and phosphorus than the original pig iron; and,second, ferruginous cinder containing the greater portion of the sulfurand phosphorus before embodied in the original pig iron and ore,substantially as and for the purpose set forth.

3. The hereinbefore described process which consists in mixing ordinarypig iron and non-manganic iron oxid ore in definite proportions;charging the same in a vertical stack furnace upon a separate anddistinct mass of fuel; preventing agitation of said mass whilesubjecting it to fusing temperature in said furnace, and, therebyproducing two products; first, iron representing the amount in said pigplus the greater part of that in said ore, and containing less sulfurand phosphorus than the original pig iron: and, second, ferruginouscinder containing the greater portion of the sulfur and hosphorus beforeembodied in the origina pig iron and ore, substantially as and for thepurpose set forth.

4. The which consists in. mixing unburned pig iron and iron ore, indefinite proportions; charging the same in a cupola furnace;continuously preventing agitation of said mass while subjecting it tofusing temperature, and, thereby producing two products; first, ironrepresenting the amount in said pig plus the greater part of that insaid ore, and containing less sulfur and phosphorus than the originalpig iron; and, second, ferruginous cinder containing the greater portionof the sulfur and phosphorus before embodied in the original pig ironand ore, substantially as and for the purpose set forth.

In testimony whereof, I have hereunto signed my name, at Philadelphia,Pennsylvania, this twelfth day of February, 1903.

MARCUS RUTHENBURG Witnesses:

ARTHUR E. PAIGE, E. L. FULLERTON.

hereinbefore described process

